Modular Building System

ABSTRACT

A modular construction member and kit including panels having sides, each side defining a matrix of holes. The matrices of holes are complementary to one another so that when connected to one another by connectors, any one of the connected sides may be coplanar with a side of the other panel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/398,573, filed Feb. 16, 2012, which claims priority to U.S.Provisional Patent Application No. 61/443,492, filed Feb. 16, 2011, thecontents of which are incorporated fully herein by reference.

BACKGROUND

More homeowners and commercial property owners are turning theirattention to structures that make outdoor living more enjoyable whetherin new construction, remodeling or new additions. In addition, manyhomeowners enjoy remodeling and making additions to their homes moregenerally to meet their personal preferences and to express their ownunique personalities and abilities. Some people prefer to hireprofessionals to do this work while many prefer to do such workthemselves.

Among the many types of projects which may be undertaken by eitherhomeowners or professionals are the design and building of structuressuch as planters, outdoor kitchens, outdoor furniture and living areas,retaining walls, and other structural building elements such aschildren's playhouses and storage facilities, as well as certain indoorstructural elements. These structures may enhance the beauty and valueof the property and provide additional living and workspace, as well asproviding challenges and opportunities for personal expression. Theseprojects are frequently custom-made using traditional building methodsand products, such as lumber, welded aluminum angle, metal studs, orconcrete blocks. In addition, there are an increasing number ofhomeowners who lack the time, tools, talent, or temperament necessary totackle a custom made construction project and seek a more modularsolution. In both custom and modular solutions, whether a project isbeing carried out by a homeowner or a professional, there is always adesire to lower costs, whether by reducing material costs and/or byreducing labor costs while maintaining or improving quality.

There have been many attempts in recent years to develop various modularor pre-manufactured construction systems geared toward both professionaland the average “do-it-yourselfer.” In some instances, these productsachieve satisfactory results, but in other instances may be difficultwith which to work or fail to provide the “custom look” many propertyowners desire. These shortcomings are particularly evident in productsdeveloped for outdoor living or hardscapes.

SUMMARY

The present invention is directed to a modular construction. Theconstruction comprises a first unitary, rigid panel, a second unitary,rigid panel, and a connector. The connector fits in one of the holes ofthe first panel, The first and second panels have a plurality of sides,each comprising a matrix of holes. The matrices of holes arecomplementary to one another such that any one of the sides of the firstpanel may be coplanar with any one of the sides of the second panel whenthe complementary holes are connected by the connector.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary structure constructed usinga modular building system in accordance with the inventive conceptsdisclosed herein.

FIG. 2 is a perspective view of a panel constructed in accordance withthe inventive concepts disclosed herein.

FIG. 2A is a perspective view of another embodiment of a panelconstructed in accordance with the inventive concepts disclosed herein.

FIG. 3 is a side elevational view of the panel of FIG. 2.

FIG. 4 is an end view of the panel of FIG. 2.

FIG. 5 is a cross-sectional view of a portion of two panels shownconnected to one another with a connector in an end-to-side orientation.

FIG. 6 is a cross-sectional view of a portion of two panels shownconnected to one another with a connector in an end-to-end orientation.

FIG. 7 is a perspective view of another embodiment of a panelconstructed in accordance with the inventive concepts disclosed herein.

FIG. 8 is a sectional view of another embodiment of another structureconstructed using the modular building system.

DETAILED DESCRIPTION

Before explaining at least one embodiment of the presently inventiveconcepts in detail, it is to he understood that the presently disclosedinventive concepts are not limited in its application to the details ofconstruction, experiments, exemplary data, and/or the arrangement of thecomponents set forth in the following description or illustrated in thedrawings. The presently disclosed inventive concepts are capable ofother embodiments or of being practiced or carried out in various ways.Also, it is to be understood that the phraseology and terminologyemployed herein is for purpose of description and should not be regardedas limiting.

Referring now to the FIG. 1, shown therein is a structure 10 whichrepresents a type of structure that may be fabricated using a modularbuilding system 12 in accordance with the presently disclosed inventiveconcepts. More specifically, the structure 10 is intended to represent astructure that may be used to form the framework of an outdoor kitchenthat includes a cabinet for housing and supporting a grill and possiblya refrigerator, cabinets, or any number of uses. Other possiblestructures to be fabricated from the modular building system 12 includeoutdoor furniture, such as chair and benches, columns, site walls,planters, retaining walls, fences, interior walls, and combinationsthereof.

Referring now to FIGS. 2-6, the modular building system 12 broadlyincludes a plurality of panels 14 and a plurality of connectors 16(FIGS. 5 and 6). The panels 14 and the connectors 16 are configured sothat the panels 14 may be assembled in a fashion that might remind oneof children's construction sets sold under the trademarks Tinkertoys®and Erector®. The panels 14 are shown to be generally flat andrectangular in shape so as to include a first side 18 and a second side20 with the second side 20 spaced apart from the first side 18 adistance to define a thickness 22 of the panel 14. In addition, thepanels 14 are shown to have a plurality of ends 24 (four peripheral ends24 a-24 d are shown in FIG. 3). While the panels 14 are illustrated asbeing generally flat and rectangular, it is to be understood that thepanels 14 can also be fabricated to have a variety of shapes, such astriangular, square, circular, octagonal, and star shaped, by way ofexample. By way of another example, a panel 14 a is illustrated in FIG.7. The panel 14 a is in the form of a concrete block, known as aconcrete masonry unit (“CMU”). The panel 14 a may be provided with aplurality of holes 30 and 32 in a manner similar to that described andillustrated in relation to the panel 14.

The panels 14 may be produced in a manner to permit for more varied orcustom configurations, such as assembling multiple panels or pieces ofpanels in a segmented arc or curved shape or assembling into anglesgreater or less than ninety degrees. In one aspect, the modular buildingsystem 12 may include a plurality of panels 14 wherein a portion of thepanels 14 have one configuration (e.g., flat, block-like, curved, columnshaped) and a portion of the panels 14 may have a differentconfiguration (e.g., flat, block-like, curved, column shaped). Inaddition, the system 12 can be sold as a kit ready to be assembled onsite into a known structure, e.g., an outdoor kitchen.

The panels 14 include a plurality of holes 30 extending through thepanel 14 from the first side 18 to the second side 20. In this case, theholes on either of the first side 18 and the second side 20 are axiallyaligned. Alternatively, or in addition, the holes 30 may extend onlypartially through the panel 14. In this case, there could be holes onlyon one side, either the first side 18 or the second side 20. Each of theends 24 a-24 d of the panels 14 is provided with a plurality of holes 32which are shown to extend partially through the panel 14. In someembodiments, the holes 32 could penetrate from one end to another end.The holes 30 and 32 are spaced so that two or more holes of the firstand second sides 18, 20 and/or the ends 24 are alignable with holes ofone or more panels 14 to effect a connection between the two or morepanels in a desired arrangement.

As illustrated in FIGS. 2-4, the holes 30 may be spaced evenly acrossthe first side 18 and the second side 20 of the panel 14 in multiplerows and columns of holes. Such rows and columns may be intersecting andmay be equally spaced. In addition to functioning as a means forconnecting the panels in the modular system, the holes may function asregister holes allowing the panels to be aligned readily on site withminimal effort, or the holes may facilitate the formation of largeropenings of various sizes which may be formed in the panels 14 forreceiving structures such as appliances, cabinetry or relatedaccessories, electrical conduit, electrical receptacles and switches,plumbing, and the like. Similarly, the holes 32 of the ends 24 a-24 dmay be spaced evenly along the ends 24 a-24 d and aligned with the holes30 of the first side 18 and the second side 20. It should beappreciated, however, that while the holes are shown as a single row,the number and spacing of the holes 30 and 32 may be varied depending onthe size and thickness of the relevant manifestation.

The holes 30 and 32 are shown as being substantially rounded. However,it is to be understood that the holes 30 and 32 can be other shapes, aswell. For example, the holes 30 and 32 can be square, triangular,rectangular, octagonal, as well as other geometrical and non-geometricalshapes. Additionally, the holes 30 and 32 can be formed where each ofthe holes 30 and 32 are the same size. Alternatively, the holes 30 and32 can be of varying sizes.

The connectors 16 (FIG. 5) are configured to be inserted into the holes30 and holes 32 to thereby interconnect two panels 14. Moreparticularly, when two panels 14 are positioned adjacent to each other,such as illustrated in FIG. 5, the connectors 16 are inserted into thehole 30 or 32 of a first panel 14 and then the opposite end of theconnector 16 is inserted into the hole 30 or 32 of the second panel 14to thereby interconnect the panels 14. While FIG. 5 illustrates twopanels 14 connected to one another in an end-to-side relationship, itwill be understood that the arrangement, or matrix of holes 30 and 32 inthe first and second sides 18 and 20 and the ends 24 a-24 d provides theflexibility of connecting panels 14 with one another in otherrelationships, such as side-to-side and end-to-end (FIG. 6). The holes30 and 32 are of a complementary form such that adjacent sides ofconnected panels are coplanar. One should appreciate that “coplanar”, asused herein, means two sides existing in the same plane, not twoabutting sides which may define a plane due to the contact of abuttingsurfaces.

Examples of suitable connectors 16 adapted to interconnect the panels 14include, but are not limited to, dowels, such as pins, rods, screws, andnuts and bolt combinations. Further, the connectors 16 can also includeone or more expandable members extending along their length where themembers apply a force to the interior surface of the holes 30 and 32when inserted therein to create a compression fitting. The connectors 16and the holes 20 and 32 could also be used in conjunction with braces(e.g., expanded metal, angle) to permit other methods of attaching onepanel to others.

As discussed above, the panels 14 are interconnected via connectors 16to thereby form a structure, such as the structure 10. The size andshape of the holes 30 and 32 are sized to accept standard connectorsappropriate for the use and dimension of the relevant embodiment of thepanel (e.g., heavier or lighter weight, etc.). The size and shape of theholes 30 and 32 can be varied depending on the dimensions of the panelsas well as the size and type of connectors 16 which are most likely tobe desirable in the intended use. More particularly, the connectors 16are sized and shaped so as to be adapted to be received by the holes 30and 32 to thereby interconnect a plurality of the panels 14. Forinstance, if the holes 30 and 32 have a round shape and a ¼ inchdiameter, then the connectors 16 are correspondingly sized and shaped(shape of the connectors may not correspond to holes for example, a staror x shape hole), Of course, the size and shape of the holes 30 and 32can be modified to correspond to connectors of particular shape andsize.

The panels 14 may be formed to have a variety of sizes and shapes andalso be formed of a material having sufficient strength to support thestructure 10 and any anticipated load. As discussed above, the structure10 can be a wide variety of structures for use indoors or outdoors. Aswould be understood in the art, the size and shape of the structure 10may determine the size, shape, arrangement of holes and material of theindividual panels 14 used to form the structure 10. In one aspect, thepanels 14 forming the structure 10 can be different sizes. Thesedifferent size panels could be originally manufactured in such sizes orresized from a more standard size by the user in a manner consistentwith their design (e.g., cutting or breaking along marked or scoredlines). In another aspect, the panels 14 can each have the same size andshape wherein the user can determine the structure 10 to be formed. Forexample, the modular system 12 can be provided as a kit including aplurality of panels 14 and connectors 16. By way of example, the panels14 may be 24 inches×36 inches×1.5 inches and include the holes 30 andthe non-penetrating holes 32 formed therein. The user of the system 10can then arrange and place the individual panels 14 in a shape, andinterconnect the panels 14 via the connectors 16, so as to form thestructure 10. Alternatively the modular system 12 could include panels14 which come in multiple sizes and configurations to build a particularstructure or structures without requiring any re-sizing if volumeallows. In all the configurations, however, the panels 14 are “rigid”,meaning that they are generally inflexible and set in a final shape. Thepanels 14 are also “unitary”, meaning that they are not comprised of anumber of different parts. Rather, each panel is the basic “unit” of themodular construction described herein. The term unitary, as describedherein, should be read to exclude “panels” which are made up of multiplesub-units.

The panels 14 can be fabricated of a variety of materials. In exemplaryembodiments, the panels 14 may be fabricated of traditional rigid,building materials that have sufficient strength and rigidity forsupporting structural loads. In addition, the panels 14 can befabricated from materials that are suitable for molding or casting, butthe panels 14 can be fabricated of other materials if desired for aparticular use. In other embodiments, the panels 14 could bemanufactured by other methods or combinations of methods (e.g.,mechanically by drilling holes). Examples of materials that may be usedto form the panels 14 include, but are not limited to, concrete, andother cementitious materials, composite materials, plastic, metal, wood,ceramic, marble, rock, and the like. When formed using concrete, theconcrete can be a traditional concrete, a lightweight concrete, and/ormaterial such as an autoclaved aerated concrete. In one aspect, thematerial forming the panels 14 can be a fireproof or fire resistantmaterial.

By way of example, the panel 14 may be formed to have the dimensions of24 inches×36 inches×1.5 inches. The panel 14 may have a plurality ofholes 30 formed on the first side 18 and extending through to the secondside 20, i.e., penetrating holes 30. In this example, the holes 30 maybe aligned in a linear fashion with the ends 24 of the first side 18,beginning two inches from the ends and repeating every two inches. Alsoin this example, the panel 14 may include the non-penetrating holes 32formed on the ends 24 and extending into the panel 14. The firstnon-penetrating holes 32 are formed two inches from the edge and thenon-penetrating holes 32 are repeated every two inches.

While the panels 14 have been described generally as having the holes 30on, or through each of the first side 18 and the second side 20, it isto be understood that other configurations are also considered withinthe scope of the present disclosure. For instance, in one aspect, thepanel 14 can include the plurality of non-penetrating holes 30 extendingfrom the first side 18, or from the second side 20, and into a portionof the thickness 22 of the panel 14. Similarly, the panel 14 can beformed wherein only a portion of the ends 24 include the non-penetratingholes 32. For example, the ends 24 a and 24 b can include thenon-penetrating holes 32. In another example, the ends 24 b, 24 c, and24 d can include the non-penetrating holes 32. As would be understood inthe art, the non-penetrating holes 32 can be formed in any or none ofthe ends 24 depending on the cost of production and the intended use ofthe panel.

Referring now to FIG. 2A, another embodiment of a panel 14 a isillustrated. The panel 14 a is similar to the panel 14 described above,except the panel 14 a is provided with one or more score lines 40 topermit the panel 14 a to be more easily broken into smaller sizes.Methods of creating score lines are well known in the art and would varydepending on the material used to form the panel 14 a. The score lines40 permit the panels 14 a to be broken on site into smaller pieces,which can then be interconnected with other unbroken panels 14 or 14 aand with other broken panels 14 a to permit the fabrication ofcustomized structures. It will be appreciated that the score lines 40may be formed in a variety of locations and patterns. For example, thescore lines 40 may be formed along the panel 14 a at selected locationson only one side of the panel to maintain the strength of the panel,such as illustrated in FIG. 2A, or score lines may be provided in auniform pattern of equally spaced score lines. Also, the score lines mayintersect the holes of the panel, or the score lines may extend betweenthe rows and columns of the holes, In an alternative embodiment, thepanel may not be scored at all, but marked with guide lines (not shown)on the sides and the ends to guide a user to form the panel to a desiredshape and size.

In one embodiment, a mortar or adhesive compound may be used inconjunction with the connectors 16 to thereby provide additionalconnection strength as well as to seal the connection area betweenadjacent panels 14.

FIG. 8 illustrates a sectional view of another version of a structure 10a fabricated using the modular building system 12. FIG. 8 illustratesthat a structure, such as the structure 10 a, may serve as asubstructure where additional facing material 52, e.g., bricks, stucco,and/or rock, can be attached to the outwardly facing portions of thepanels 14 forming the structure 10 a.

The holes 30 and 32 may allow connection of the panels 14 (or blocks orother shapes having the holes on each side) in vertical, horizontal, anddiagonal planes. In addition, the panels 14 can be trimmed to allow acustom configuration. This use of holes 30 and 32 on all surfaces can beapplied to any regular geometric shape that can be cast, molded, piercedor drilled.

An advantage of the system 12 is that standard, familiar, and intuitiveconstruction methods in combination with standard commercial fastenersand hardware can be used to interconnect the panels 14. For example,other fasteners and hardware that can be used include, but are notlimited to: all-thread with or without nuts and washers; bolts withnuts, washers, and fender washers; smooth pins; modified turnbuckle;plumber's tape; angle iron with hole(s) for anchor bolt; expanded metalplates and braces; bars to support custom horizontal and vertical panels(all-thread, smooth bar and rebar) cut for such things as shelves andrecesses; standard woodworking hardware can be used to support suchitems as shelves and drawers; custom fasteners for custom panelconfigurations or temporary fasteners to stabilize the system prior tofinal assembly (e.g., before connectors are tight and in place); rollpin; nylon strapping with clips; electrical ties; anchors with screw ornail expander;

A number of custom or standard tools can be used in the assembly. Forexample, a masonry saw can be used to provide for custom shaping of thepanel 14, manually, in the field. Or as another example, a jig (notshown) may be used for forming holes of the same diameter and spacing asthe holes 30 and 32 in the newly exposed end of the panel 14 after thepanel 14 is cut or broken along one of the score lines, as well forforming holes in a concrete foundation on which the structure is to beerected or, for example, a countertop to be attached to a structure,such as depicted in structure 10.

From the above description, it is clear that the inventive conceptsdisclosed herein are well adapted to carry out the objects and to attainthe advantages mentioned herein, as well as those inherent in theinvention. While presently preferred embodiments of the inventiveconcepts have been described for purposes of this disclosure, it will beunderstood that numerous changes may be made which will readily suggestthemselves to those skilled in the art and which are accomplished withinthe spirit of the inventive concepts disclosed.

What is claimed is:
 1. A modular construction comprising: a firstunitary, rigid panel having a plurality of sides, each of the pluralityof sides comprising a matrix of holes; a connector for fitting withinone of the holes of the first panel; and a second panel having aplurality of sides, each of the plurality of sides comprising a matrixof holes, each of the matrices of holes of the second panel adapted tobe complementary to each of the other matrices of holes of the firstpanel such that any one of the sides of the first panel may be coplanarwith any one of the sides of the second panel when the complementaryholes are connected by the connector.
 2. The modular construction ofclaim 1 wherein the coplanar side of the second panel is identical tothe coplanar side of the first panel when connected by the connector. 3.The modular construction of claim 1 wherein the coplanar side of thesecond panel is different from the coplanar side of the first panel whenconnected by the connector.
 4. The modular construction of claim 3wherein one of the other sides of the first panel is also coplanar withanother side of the second panel creating a 90 degree corner.
 5. Themodular construction system of claim 1, wherein the holes of at leasttwo of the sides are arranged in a plurality of intersecting rows andcolumns of holes.
 6. The modular construction system of claim 5, whereinthe holes of each of the rows and the columns of holes are equallyspaced.
 7. The modular construction system of claim 1, wherein the holesof at least two sides meet to form a plurality of through holes.
 8. Themodular construction of claim 1, wherein the connector comprises adowel.
 9. The modular construction of claim 1, further comprising aplurality of braces connectable to the panels.
 10. The modularconstruction system of claim I wherein the panel comprises precastmasonry.
 11. The modular construction system of claim 1 wherein thefirst panel and the second panel are identical.
 12. A modular buildingkit, comprising: a set of rigid, unitary panels, each of the panelshaving a plurality of sides, each of the sides comprising a matrix ofholes having a spacing length between holes and an edge length between ahole which is closest to an edge of its side and the side; and a meansfor connecting the panels to one another comprising one of the group ofdowel rods, screws, nuts and bolts, pins, and expandable members,wherein at least a portion of the matrix of holes of one of the panelsis capable of being connected with holes of another one of the panelsand in such a way as to form a composite load bearing structure; whereinthe spacing length of the matrix of holes on one of the panels isidentical to the spacing length of at least a portion of the matrix ofholes of each of the other panels and wherein the edge length of thematrix of holes on one of the panels is identical to the edge length ofthe other panels.
 13. The kit of claim 12 wherein each of the panelscomprise six sides.
 14. The kit of claim 13 wherein the matrix of holesof at least two of the sides of each of the panels are arranged in aplurality of intersecting columns and rows.
 15. The kit of claim 14wherein the holes of each of the rows and the columns of holes areequally spaced.
 16. The kit of claim 15 wherein the holes of at leasttwo sides meet to form a plurality of through holes.
 17. The kid ofclaim 16 wherein the panels comprise precast masonry.
 18. The kit ofclaim 17 further comprising a plurality of braces connectable to thepanels.
 19. The kit of claim 18 wherein the panels are arranged to forman outdoor kitchen.
 20. A method for constructing an object comprising:providing a first rigid, unitary panel having six sides, each of the sixsides comprising a matrix of holes; providing a second rigid, unitarypanel having six sides, each of the six sides comprising a matrix ofholes; connecting the first panel to the second panel by placing aconnector into a plurality of the holes of the first panel and acorresponding plurality of holes of the second panel to form a compositestructure; wherein each of the matrices of holes of the second panel isadapted to be complementary to each of the other matrices of holes ofthe first panel such that any one of the six sides of the first panelmay be coplanar with one of the six sides of the second panel when theappropriate corresponding plurality of holes are connected by theconnector.
 21. The method of claim 20 further comprising the step ofconnecting additional unitary panels to the composite structure to forma load-bearing structure.